4" Air Intake System - Cheap
 

First I want to thank 53 Willys who has shared his Whistler Intake that I'm sure most of you have read about (which is pretty awesome by the way).

So here's what I did...

I went to www.intakehoses.com, and bought (2) 4" elbows (long radius not short radius which they sell as well) and a 6" Long 4" Alum tube. The dimensions work out perfectly to replace you stock tubing all the way to the stock airbox. So, put 1 elbow on your turbo, then the alum tubing pointing upward and the other elbow connects the tubing to the connection on the airbox.

You definitely here your turbo whistle and feel the difference in throttle response

I also bought (4) 4" T-Bar clamps to connect everything.

With shipping it came out to $60

http://intakehoses.com/Merchant2/mer...gory_Code=9DEH

http://intakehoses.com/Merchant2/mer...gory_Code=SIT7

http://intakehoses.com/Merchant2/mer...gory_Code=TBC5


It's definitely cheaper than the 4" silicone "cool" tube

that's what i'm trying now felter is on the way.

no pics????[coffee]

I'll take some when I get home today, it seems to be working really well though. The dirty filter indicator shows the filter being dirty (half way compressed), but the filter is clean. Do think its because the new tubing allows for more flow than the stock box can support?

I'd hate to have to cut holes in the darn thing. I'd like to figure out how to get a 4" diameter Amsoil Cone filter inside the stock box with the 4" tubing. Maybe that will be part II

I just ordered the parts you have listed. Do you have any suggestions from when you installed yours to make my install easier?

Yeah here's a few pointers,

1) If you buy the T-Bolt Clamps, it takes an 11mm socket/wrench to tighten them. Pretighten the clamps before installing them, because it takes a lot of turns before it snugs up on the hose

2) When you get the parts clean them with WD40 and wipe them down well. The WD40 cleans rubber easily and will make sliding it over the tubing easier

3) The side of the 4" elbow that connects to the turbo needs to be trimmed about a 1/2" to clear the oil filter. I used household scissors. Snip from the edge in and then work your way around the radius. Note my truck is and 03, so there maybe more/less clearance on the 04.5 and newer models. Therefore before cutting the elbow slide it onto the turbo first to check clearance.

4) install the parts from the turbo to the airbox, leaving your clamps loose until you have it all fitted.

I'll post pics

http://img381.imageshack.us/img381/2...1668xg4.th.jpg

http://img254.imageshack.us/img254/2...1667zd3.th.jpg

Thanks for the tips. Once you install your aftermarket filter, I will be looking forward to seeing your build up on that. Thanks!!

Just wondering if any of you guys have tried it, it's been working well for me

That looks like a VERY nice/clean install! Only problem I see is that the hose is only rated at 250-275 degrees. Do the temps get that high right there?

I have the AFE Stage 2 intake on my truck, and the original hose that came with the intake ended up getting a tear in it. I am not 100% positive that it was because of the heat, but part of the hose did melt onto the turbo. I contacted AFE and they immediately sent me out a new hose that was a lil beefier.

I would keep an eye on that. Definitely don't want that hose to melt/rip/tear and start sucking up debris. That would be costly!

Jared

Thanks for the heads up, I inspected the hose and everything is in good shape, I've been running the setup for about 3 weeks now, but I'll keep my eye on it.

I am running the exact same setup on my 06 mega with the AFE Proguard 7 drop in filter. Also had to trim about 1/2" on the elbow to the turbo due to the oil filter. No heat issues thus far. I ended up using the factory band clamps with no issues instead of T-bars.

Nice thing is if something fails and need to take in for warranty work you can pull off this and put the stocker back on as one piece. Can you say paranoid? :)

Where can you buy the drop in filter?

I did the same thing to my truck 40,000 miles ago and have not had any problems with heat melting or causing cracks in the rubber 90's. I picked up my stuff locally at a filter shop for like 30 dollars. Works good.
Mark

I got mine from Baxter Auto Parts locally. I've seen some other threads on peeps using the amsoil dry oem style drop in filter also. Love my AFE so far. Tube seems clean, no residue or dust.

Just ordered the parts. Got the clamps too -- didn't need them but wanted to be able to swap tubes quickly if I wanted to take her in for service....

$60.53 total w/shipping.

Looking forward to hearing the difference!!!